2004 SUBARU FORESTER engine

AC-20
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
C: CAUTION
1. HFC-134a A/C SYSTEM
 The cooling system components for the HFC-
134a system such as the refrigerant and compres-
sor oil are different from the old conventional HFC-
12 system components and they are incompatible
with each other.
 Vehicles with the HFC-134a system can be iden-
tified by the label (A) attached to the vehicle.
Before maintenance, check which A/C system is in-
stalled in the vehicle.
2. COMPRESSOR OIL
 HFC-134a compressor oil has no compatibility
with that for R12 system.
 Use only the manufacturer-authorized compres-
sor oil for the HFC-134a system; only use
ZXL200PG.
 Do not mix multiple compressor oils.
If HFC-12 compressor oil is used in a HFC-134a A/
C system, the compressor may become stuck due
to poor lubrication, or the refrigerant may leak due
to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a HFC-12 A/C system, the durability of the
A/C system will be lowered.
 HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere us-
ing a plug or tape. In order to avoid moisture, store
the oil in a container with its cap securely closed.
3. REFRIGERANT
 The HFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system.
 If an incorrect or no refrigerant is used, poor lu-
brication will result and the compressor itself may
be damaged.
4. HANDLING OF REFRIGERANT
 The refrigerant boils at approx. −30°C (−22°F).
When handling it, be sure to wear safety goggles
and protective gloves. Direct contact of the refriger-
ant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
 Do not heat a service can. If a service can is di-
rectly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use hot water in 40°C (104°F) max.
 Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
 When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an ex-
plosion of the can.
 Provide good ventilation and do not work in a
closed area.
 In order to prevent global warming, avoid releas-
ing HFC-134a into the atmosphere. Using a refrig-
erant recovery system, discharge and reuse it.
AC-00006
(A)
(A) Goggles
(B) Gloves
(C) Avoid open flame
(D) No direct heat on container
(E) Do not discharge
(F) Loosen
(A)
(B)
(C) (D)
(E) (F)
AC-00007

AC-25
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Pressure with Manifold Gauge Set
2. Refrigerant Pressure with Manifold Gauge Set
A: OPERATION
1) Place the vehicle in the shade and draftless condition.
2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the hood.
5) Increase the engine speed to 1,500 rpm.
6) Turn ON the A/C switch.
7) Turn the temperature control dial to MAX COOL.
8) Set the air inlet select switch to RECIRC position.
9) Turn the fan dial to HI.
10) Read the gauge.
Standard:
Low pressure: 127 — 196 kPa (1.3 — 2.0 kg/cm
2, 18 — 28 psi)
High pressure: 1,471 — 1, 667 kPa (15 — 17 kg/cm2, 213 — 242 psi)
Ambient temperature: 30 — 35
°C (86 — 95°F)
B: INSPECTION
Symptom Probable cause Repair order
High-pressure side is unusually high. Defective condenser fan motor
 Clogged condenser fin
 Too much refrigerant
 Air inside the system
 Defective receiver dryer Replace the fan motor.
 Clean the condenser fin.
 Discharge refrigerant.
 Replace the receiver dryer.
 After reevacuating the receiver dryer,
charge appropriate amount of refriger-
ant.
High-pressure side is unusually low. Defective compressor
 Not enough refrigerant
 Clogged expansion valve
 Expansion valve frozen temporarily by
moisture Replace the compressor.
 Check for leaks.
 Replace the expansion valve.
 Fully evacuate the expansion valve.
Low-pressure side is unusually high. Defective compressor
 Defective expansion valve
 Too much refrigerant Replace the compressor.
 Replace the expansion valve.
 Discharge refrigerant.
Low-pressure side is unusually low. Not enough refrigerant
 Clogged expansion valve
 Expansion valve frozen temporarily by
moisture
 Saturated receiver dryer  Check for leaks.
 Replace the expansion valve.
 Replace the receiver dryer.

AC-26
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Recovery Procedure
3. Refrigerant Recovery Proce-
dure
A: OPERATION
CAUTION:
 During operation, be sure to wear safety gog-
gles and protective gloves.
 Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrig-
erant from the A/C system and reuse it.
 When reusing the discharged refrigerant, keep
service cans on hand. Because the discharge
rate with the recovery system is approx. 90%, ser-
vice cans are necessary to charge the refrigerant.
 Follow the detailed operation procedure de-
scribed in the operation manual attached to the
refrigerant recovery system.
1) Perform the compressor oil return operation.

2) Stop the engine.
3) Make sure the valves on low-/high-pressure
sides of manifold gauge set are fully closed.4) Install the low-/high-pressure hoses to the ser-
vice ports on the low-/high-pressure sides of the
vehicle respectively.
5) Connect the center hose to the refrigerant recov-
ery system.
6) Follow the operation manual to activate the re-
frigerant recovery system.
L: Low-pressure gauge
H: High-pressure gauge
(1) Low-pressure valve
(2) Vacuum pump valve
(3) High-pressure valve
(4) For low-pressure
(5) For vacuum pump
(6) For high-pressure
AC-00146
(2) (4)
(5)(6)
(3)(3)
(2) (1)H L
(1)
(1) Low-pressure service port
(2) High-pressure service port
(3) Close
AC-00147
(3) (2) (1)

AC-28
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
6) Leave it at least 5 to 10 minutes after closing the
valves on low-/high-pressure sides, and then check
the low-pressure gauge reading for any changes.
When the gauge reading changes, this is a sign of
leakage. Check the pipe or hose connector points,
and repair if necessary. Repeat the procedure from
1) after repairing the faulty part.
7) If there are no leaks, further evacuate the sys-
tem 20 to 30 minutes.
8) Close all valves and stop the vacuum pump.
9) Following the can tap operation manual instruc-
tions, install it to refrigerant can.
10) Disconnect the vacuum pump from center
hose, and connect the hose to tap valve.
11) When a 13.6 kg (30 lb) refrigerant container is
used, measure the refrigerant amount in use using
a weighting scale before connecting to center hose.
12) Open the valve on HFC-134a source.13) Loosen the center hose connection on manifold
gauge (if applicable, press a purge valve on mani-
fold gauge) only for a couple of seconds to allow
the air in the center hose to escape by the refriger-
ant.
14) Make sure that the high-pressure valve of man-
ifold gauge is closed, and then open the low-pres-
sure side valve only to charge the refrigerant.
CAUTION:
Do not open the high-pressure valve. Be sure to
open the low-pressure valve.
15) Close the low-pressure valve when the low-
pressure gauge reading reaches 200 kPa (1,500
mmHg, 59.1 inHg).
16) Using a leak tester, check the system for refrig-
erant leaks.
17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.
18) If the HFC-134a source is empty, close the low-
pressure valve and then close the valve on can tap
before replacing the empty source. Restart charg-
ing operation after replacing the HFC-134a source
with a new one and purging.
19) Close the low-pressure valve if the charge rate
of refrigerant becomes worse.
20) Confirm that both the low-/high-pressure
valves are closed. Start the engine with A/C switch
OFF.
21) Quickly repeat A/C switch ON-OFF cycles a
few times to prevent initial compressor damage.
(1) Tap valve
(2) To center manifold hose
(1) Refrigerant container (HFC-134a)
(2) Weighting scale
AC-00214
(1)
(2)
AC-00215
(1)
(2)
(1) Open
(2) Close
AC-00216
AC-00217
(1)
(2)

AC-29
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
22) Set up the vehicle to the following status:
 A/C switch ON
 Engine running at 1,500 rpm
 Blower speed setting to “HI”
 Temperature setting to “MAX COOL”
 Air inlet setting to “RECIRC”
 Window open
23) Open the low-pressure valve and charge the
specified amount of refrigerant.
24) Close all valves and disconnect the hoses from
service port after charging the refrigerant.
25) Install the cap to service port.

AC-30
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Leak Check
5. Refrigerant Leak Check
A: INSPECTION
1) Operate the A/C system for approx. 10 minutes,
and confirm that the high-pressure side shows at
least 690 kPa (7.03 kg/cm
2, 100 psi). Then stop the
engine to start the leak test.
2) Starting from the connection between the high-
pressure pipe and evaporator, check the system for
leaks along the high-pressure side through the
compressor. The following items must be checked
thoroughly.
3) Check the joint and seam between the pressure
switch (triple pressure switch) and high-pressure
pipe.
4) Check the connections between the condenser
and pipes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between the compressor and
hoses.
6) Check the machined area of compressor and
other joints on the compressor.
7) Check the compressor shaft seal at the area
near the center of compressor clutch pulley.
Some shaft seals show a slight amount of leakage
about 28 g (1.0 oz) per year. This is not a problem.
8) Starting from the connection between the low-
pressure pipe and evaporator, check the system for
leakage along the low-pressure side through the
compressor. The following items must be checked
thoroughly.
 Connection between two parts
 Connection between the pipe and plate
9) Visually check the rubber area of the flexible
hose for cracks.
Check the entire length of the flexible hose, espe-
cially the connection with the metal hose end.CAUTION:
Carefully check the external surface of hoses
and tubes at approx. 25 mm (0.98 in) per sec-
ond.
10) Disconnect the drain hose from the heater
case, and check the hose end for at least 10 sec-
onds.
After the test is finished, reconnect the drain hose.
11) Turn the ignition switch to ON, and run the
blower at high speed for 1 minute. Stop the blower
to check the ventilation grille on the instrument pan-
el. While moving the tester closer to the grille, run
the blower for 1 or 2 seconds, then stop it. Check
the grille at that point for at least 10 seconds.
12) Check the valve in the service port.
13) Visually check the rubber seal in the service
port cap.
AC-00035
(A) Flexible hose
AC-00036
(A)
AC-00037
AC-00038

AC-31
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Compressor Oil
6. Compressor Oil
A: OPERATION
NOTE:
Before making repairs, conduct the oil return oper-
ation to return the compressor oil in circulation with
the refrigerant to the compressor.
1) Increase the engine speed to 1,500 rpm.
2) Turn ON the A/C switch.
3) Turn the temperature control dial to MAX COOL.
4) Set the air inlet select switch to RECIRC posi-
tion.
5) Turn the fan dial to HI.
6) Leave in this condition for 10 minutes.
B: REPLACEMENT
NOTE:
 If a component is replaced, add an appropriate
amount of compressor oil (same as the amount of
remaining oil in removed component).
 When replacing the compressor, the new com-
pressor will already have the specified amount of
oil in it. Install the new compressor after removing
the same amount of oil that is remaining in the com-
pressor removed.
Replacement parts Amount of oil replenishment
EvaporatorApprox. 50 cm
3
(1.7 US fl oz, 1.8 Imp fl oz)
CondenserApprox. 30 cm
3
(1.0 US fl oz, 1.1 Imp fl oz)
HoseApprox. 10 cm
3
(0.4 US fl oz, 0.4 Imp fl oz)
Receiver dryerApprox. 10 cm
3
(0.4 US fl oz, 0.4 Imp fl oz)

AC-36
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Compressor
11.Compressor
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
1) Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.3 — 0.6 mm (0.0118 — 0.0236 in)
2. MAGNETIC CLUTCH OPERATION
1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to the
No. 3 terminal of the compressor connector.
3) Make sure the magnet clutch engages.
If NG, replace the compressor.
B: REMOVAL
1) Perform the compressor oil return operation.

2) Turn the A/C switch OFF and stop the engine.
3) Using the refrigerant recovery system, discharge
refrigerant. ant Recovery Procedure.>
4) Disconnect the ground cable from battery.
5) Remove the V-belt. MOVAL, V-belt.> MOVAL, V-belt.>
6) Remove the generator. REMOVAL, Generator.>
7) Remove the low-pressure hose and high-pres-
sure hose.
8) Disconnect the compressor harness from body
harness.9) Remove the bolts to remove compressor brack-
et.
10) Remove the bolts and then separate compres-
sor and bracket.
C: INSTALLATION
1) Install in the reverse order of removal.
2) Replace the O-rings on low-/high-pressure hos-
es with new ones, then apply compressor oil.
3) When replacing compressor, adjust amount of
compressor oil. Compressor Oil.>
4) Charge refrigerant. TION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. UNIT, COMPONENT, General Description.>
NENT, General Description.>
AC-00048
AC-00049
AC-00336
AC-00051